Centralized filtration system?
Absolutely not!

We report the case history of LONATI S.P.A

The CNC machining centers Dept., core product of mechanical production in Lonati, has been the subject an important intervention of modernization with the disposal of their centralized system for fume generated during the machining processing of their machining centres. They dismantled the centralized system, replacing it with AR filtrazioni mist collectors installed on single machine. 

A modular approach

The centralized system for suction of fume generated during machining processing of machine tools, because of its characteristics, was worried about the consequences of any blocking. «As maintenance manager – Mr. Pasotti explains – I need to find a way (1) to avoid that a problem on the exhaust system can lead to a production down-time on all the 47 connected machine tools,

with heavy consequences for our company. Moreover, because of the large dimensions, the repairs on a centralized system would have taken several days to be concluded». Lonati had not only to ensure the continuity of production, but they had another criticalities to overcome regarding their centralized system. « An important issue is the recovery of the neat oil (in Lonati we work with neat oil only, NDR): the centralized system that we used in the past, mixed the oil coming out of several machine tools. But these machines utilize different characteristic of oil and this mix was keeping us to reuse from it, particularly for machine with delicate metal working».
The centralized system and its canalization had a considerable impact in the workshop, becoming slightly complicated any procedure of modernisation or lay-out modification. (2)«In Lonati the lay-out modifications are not uncommon and every time we had to rewire the plant by modifying the pipes. Moreover, all these pipes reduced the brightness in the workshop, worsening the comfort in the working environment». 

Last but not least, not to be underestimated the implications for (3) fire safety level.
«If a machine catches on fire and the fire reaches the connection pipes of the centralized system, it can spread all over the workshop, causing very serious damage». After this analysis, Lonati decided to change their approach to the smoke management theme, replacing a centralized system with a new generation of on-board mist collectors AR filtrazioni. 

«We needed – synthesizes Pasotti – to make completely independent every  machine tool, regarding the production, the recovery of the oil and the fire safety».

The cooperation with AR filtrazioni began with the decision to pass from a centralization to single (on- board) plants, installing the first pilot air cleaner for fume filtration on one of the more recently machining centre.

“After a yearly test – underlines Angelo Riceputi President of AR Filtrazioni – with Lonati we decided to equip every machine tool with an air cleaner, taking care to optimize them on the basis of the characteristics of the single machine and the metal working (for example the aluminum metal working emits more fume.) 

We utilized a modular combined filtration system for a longer life of the last stage of EPA filter.

Some machines are equipped with a high performances pre-filtration system, with the centrifugal condensed technology, applied by AR Filtrazioni.” With the installation of the first 47 AR Filtrazioni mist collectors, the machine workshop was disconnected from the centralized plant, avoiding the worry of downtime in case of dysfunction of the centralized system.

“Now if there is a problem on a filtration system it’s enough to sign off the involved machine – underlines Pasotti -, but the production can go ahead. 

Furthermore, the maintenance of the AR Filtrazioni plants is very easy and speedy.

(4) Significant quantity and quality results regarding the recovered oil; “Every single air cleaner recovers the oil, conveying it immediately to the machine tool, avoiding contamination with another types of oil. In this way we reduced of 15% our oil consumption and increased the efficiency and quality of our metal workings.”

The AR filtrazioni plants condensed more than 80% of the neat oil,, connecting directly into the machine tool.

To quantify the savings in Lonati we consider these factors by a symply multiplication:

– 47 their machine tools, working with neat oil;
– 6 litres  the re-condensed and recovered oil,  conveyed directly into each machine tool, thanks to the centrifugal system of AR filtrazioni;
– considering an average price of 4 euro per liter of neat oil:

6l x 4€ x 47 M.U. x 365gg = 411.720 euro/ euro the early saving of Lonati.

(5) This savings induced Lonati to choose AR filtrazioni mist collectors, dismantling their still-active centralized system for the oil mists collection.

(6) Big advantages in the workshop,too, full of light and clear  of all the connection pipes of the centralized system, coming compliments of the labor unions and allowing the possibility to install a  new led lighting.  

(7) “ The smell of oil is vanished – explains the environment responsible of Lonati  – I didn’t image to reach this result.”

(8) Furthermore, without a centralized system connecting air outside, we  made a considerable contribution in reducing energy consumption. 

AR filtrazioni determines a yearly energy saving of euro 415,00 for each ARNO 1VF plant WITH 1700 CM/h (considering a thermal delta of 15° during the winter months).

Giving substance: 47 machine tools x 415,00 euro= 19.505,00 euro saved on the heating costs of the warehouse.

“ With the installation of air cleaners on-board of every single machine tool, we avoid the risk of fire propagation. Moreover we are utilizing rubber pipes between the machining centers and the filtration units; in this way, in case of fire, the flame cannot arrive to the air cleaners.”

Concerning the maintenance, very satisfy result achieved. AR Filtrazioni is responsible for maintenance and installation and “ As mutually agreed with Lonati – explain AR Filtrazioni engineers – we agreed to control the spare parts condition every 6 months because their duration depends of the metal working and we change them only when necessary. We issue a certificate with the detail of each plant and maintenance date as the rules of Lombardy Region impose.

«In agreement with Lonati – explain the AR Filtrazioni technicians – we have chosen to carry out six-monthly checks during which our experts analyze the filters, whose duration also depends on the machining performed by the machine, and replace them only when necessary.

We issue the customer with a summary table of the maintained system, a document that is required by law in Lombardy, with details of each intervention performed.